Practice Test Geeks(SAW) Submerged Arc Welding Certification Practice Test
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Welding Techniques & Process Control Flashcards

7 cards from real SAW practice questions. Tap to flip, then mark Knew It or Still Learning — missed cards come back until you master them.

Read the first 7 Welding Techniques & Process Control flashcards as text

  1. What does a high basicity index (BI > 2.5) flux in SAW primarily contribute to the weld deposit?

    Answer: Improved Charpy impact toughness and low hydrogen content

    High-basicity fluxes produce lower levels of oxygen and hydrogen in the weld metal, significantly improving notch toughness at low temperatures.

  2. In SAW, what is the consequence of flux depth (burden) being too shallow?

    Answer: The arc breaks through the surface, causing flashing and spatter

    Insufficient flux depth fails to contain the arc, resulting in arc flash, visible sparks, spatter, and a rough bead surface.

  3. What is the advantage of using DCEN (electrode negative) in SAW compared to DCEP?

    Answer: Higher deposition rate with reduced penetration, suitable for overlay or cladding

    DCEN concentrates more energy at the electrode tip rather than the workpiece, melting the wire faster for higher deposition with shallower penetration.

  4. A SAW procedure qualifies at a heat input of 50 kJ/in. If the production weld's heat input drops to 35 kJ/in, what is the primary concern?

    Answer: Insufficient fusion and possible hydrogen cracking from faster cooling

    Lower heat input than qualified increases cooling rate, which can cause lack of fusion and raises the risk of hydrogen-induced cold cracking in the HAZ.

  5. Which SAW process variant uses the electrode connected in series between two workpieces rather than between electrode and work?

    Answer: Series SAW (arc between two electrodes)

    In series SAW, two electrodes form the arc between themselves above the joint, heating the workpiece by radiation and conduction for very high deposition with minimal penetration.

  6. When qualifying a SAW procedure under AWS D1.1, changing the wire diameter from 5/32" to 3/16" requires what action?

    Answer: A new procedure qualification test (PQT)

    Under AWS D1.1, a change in electrode (wire) diameter beyond the qualified range is an essential variable requiring a new procedure qualification test.

  7. What process control strategy is used to maintain constant arc length in SAW when using a constant-current (CC) power source?

    Answer: Voltage-sensing wire feed speed control (arc voltage feedback)

    With a CC source, arc length is maintained by a wire feeder that senses arc voltage and automatically speeds up or slows down feed to keep voltage constant.